Octane Fitness Q45 User manual

Q45/Q45e/Q45ce

Q45/Q45e/Q45ce
Service Manual
Table of Contents
SECTION I: General Service Tips
Part Locations............................................................................................................................ 1.1
Diagnostic Mode Settings and Error Codes............................................................................... 1.2
Suggested Dealer Stock List ..................................................................................................... 1.3
SECTION II: Troubleshooting Tips
Power/Electrical Issues.............................................................................................................. 2.1
Resistance Issues...................................................................................................................... 2.2
Console Issues .......................................................................................................................... 2.3
Noise Issues .............................................................................................................................. 2.4
Heart Rate Monitoring Issues .................................................................................................... 2.5
SECTION III: Part Replacement & Adjustment Procedures
Roller Wheel Replacement........................................................................................................ 3.1
Pedal Arms Replacement .......................................................................................................... 3.2
Rails Replacement..................................................................................................................... 3.3
Adjustable Link Assembly Replacement.................................................................................... 3.4
Actuator Nut Replacement......................................................................................................... 3.5
Retaining Bracket Replacement ................................................................................................ 3.6
Belt Tensioner Replacement...................................................................................................... 3.7
Brake Assembly/Pulley Replacement........................................................................................ 3.8
Servomotor Replacement.......................................................................................................... 3.9
Brake Cable Adjustment .......................................................................................................... 3.10
Upper and Lower Wiring Harnesses Replacement...................................................................3.11
Pivot Shaft Replacement ......................................................................................................... 3.12
Speed Sensor Replacement.................................................................................................... 3.13
Heart Rate Sensor Cable Replacement .................................................................................. 3.14
Heart Rate Contact Handgrip Replacement ............................................................................ 3.15
Console Replacement ............................................................................................................. 3.16
Console Overlay Replacement................................................................................................ 3.17
Console Software Micro-Controller Replacement.................................................................... 3.18
Controller Board Replacement ................................................................................................ 3.19
Limit Switch Assembly Replacement....................................................................................... 3.20
SECTION IV: Supporting Documentation
Q45/Q45e/Q45ce/Q45ce Assembly Instructions
Q45/Q45e/Q45ce/Q45ce Operations Manual
Q45/Q45e/Q45ce Service Manual 04.06v2

Notes

Figure 1.1
Figure 1.3
Right
Clevis
Notice step
orientation to
outside of
machine
Figure 1.2

*WARNING: LINKAGES PRESENT
NUMEROUS PINCH POINTS.
USE CAUTION TO AVOID INJURY.
Q45 1.1
SECTION I: General Service Tips
1.1 Part Locations
Figure 1.1 highlights the locations of the main components of the Q45/Q45e/Q45ce linkage system. Figure 1.1 represents
units with Serial Numbers ranging from ________________ to ________________; Figure 1.2 illustrates the modied
location of the controller board in units having Serial Numbers _______________ and higher.
“Right” and “Left” assemblies and motors are indicated by “R” and “L”, respectively, either etched into the metal or on a
decal.The right and left pedal arms are differentiated by the stepped out clevis; the step should be oriented to the outside
of the unit, as shown in Figure 1.3. The following key components are not shown in the picture:
Moving handlebars
Speed sensors (2), mounted onto frame
Two-piece wire harness, coming down from the console

Q45 1.2
Figure 1.4

Q45 1.2
1.2 Diagnostic Mode Settings and Error Codes
The Q45/Q45e/Q45ce elliptical machine offers a diagnostics mode to test the console and brake functions. To
enter the diagnostics mode, hold down the Time +/- and Level +/- keys simultaneously for three (3) seconds. The
tests and results are displayed in the console windows (as shown in Figure 1.4, upper and lower keypads), as
indicated in the chart below. The rst three tests (D1 through D3) run automatically. You must use the +/- keys to
navigate through the remaining diagnostic tests options, pressing Enter to select the test you want to perform.
The following diagnostics are available on the Q45/Q45e/Q45ce:
Description Matrix Window 1 Window 2 Window 3 Window 4
Check memory D1
Brake motor test RESISTANCE
TEST
D2 1-30
Check all keys
(You must press each
key and listen for the
beep to verify that it
works properly before
you can move on to the
next test).
D3
Check all LEDs (Machine
cycles through all LEDs
in all windows; when you
have veried all LEDs,
press any + key to move
to the next test.)
All LEDs light
up
All LEDs
light up
All LEDs
light up
All LEDs
light up
All LEDs
light up
Software version Version # Version # Version # Version #
Total distance of machine TD Distance
value
Total time of machine
usage
TT Usage
hours
Total motor on time MOT Motor on
hours
When you rst enter the diagnostic mode, three customization features are displayed which allow some default
settings to be changed. Press any + or - key to change a setting; press Enter to advance to the next feature.
Description Matrix Window 1
SmartStride RPM Delta: Allows you
to set the RPM delta. Range is 5 to
15 RPM.
SSRD Value in RPM
(Default = 5)
Smart Stride Check Time: Allows
you to set the number of seconds
between RPM checks after the stride
motors stop moving. Range is 5 to
15 seconds.
SL Value in Seconds
(Default = 5)
Warm-up on/off: Allows you to
de-activate the 3-minute warm-up
period for non-heart rate-controlled
programs (P2-P5 and P11-P15).
WUP “On” or “Off”
(Default = ON)
To exit the diagnostics and customization mode and save your changes, press the Pause/Clear button twice
within 2 seconds.

Error Codes
The Octane Q45/Q45e/Q45ce elliptical machine displays four errors indicating faulty components:
Display Denition
Err1 Servomotor (brake motor) issues
Err2 Left stride motor issues
Err3 Right stride motor issues
Err4 RPM of #1 route
Err5 RPM of #2 route
Err6 Low limit switch issue, left stride motor
Err7 High limit switch issue, left stride motor
Err8 Low limit switch issue, right stride motor
Err9 High limit switch issue, right stride motor
Err10 EEPROM
Err11 Communication issues
Please contact Octane Fitness Customer Service for guidance in diagnosing and resolving these error codes.
Resolution may require replacement of parts. Octane strongly suggests that you keep an inventory of key parts
on hand so that you and your customer will not experience delays in resolving issues due to parts ordering and
shipment. Refer to the Suggested Dealer Stock List for more information.
Q45 1.2

1.3 Suggested Dealer Stock List
Octane Fitness suggests that dealers and service technicians maintain a minimal inventory of commonly needed
parts and supplies so that customer service issues may be promptly and accurately addressed. The following
table identies parts and recommended stock quantities for your inventory.
Part Number Description Suggested
Quantity
10B722JM CHEST STRAP WITH TRANSMITTER 2
110428CU ELASTIC STRAP FOR CHEST MONITOR 2
10B727R2 HR SENSOR CABLE ONLY 2
1005-SPS4501-01 Q45 POWER TRANSFORMER 2
10B827KH Q45 ACTUATOR NUT LEFT 2
10B827HB Q45 ACTUATOR NUT RIGHT 2
10B826KW Q45 ADJ LINK ASS’Y LEFT W/MOTOR 2
10B826KV Q45 ADJ LINK ASS’Y RIGHT W/MOTOR 2
10B826KX Q45 BELT TENSION ASS’Y W/BEARING 2
10B826KG Q45 BRAKE ASS’Y 1
10B826K9 Q45 BRAKE CABLE 2
10B826K8 Q45 CONTROLLER BOARD 3
10B826K3 Q45 DC SERVO MOTOR 2
257226LB Q45 DRIVE BELT 2
29WH2 Q45 SHAFT RETAINER 4
10B8291H Q45 ROLLER WHEELS 8
10B8291V Q45/E HARDWARE PACK 3
SHROUD, BACK -- NO DECALS Q45 2
Q45 SHROUD, LEFT WITH CHROME PIECE 2
Q45 SHROUD, RIGHT WITH CHROME PIECE 2
TOP SHROUD 2
Q-CONS-SIM CONSOLE, STANDARD 2
Q-CONS-DLX CONSOLE, DELUXE 2
Q45 SMART DRIVE CHIP 2
10B8287J Q45 LOWER WIRE HARNESS 1
10B826JY Q45 UPPER WIRE HARNESS 1
10B826JX SPEED SENSOR -Q45 2
100088-001 STATIONARY GRIPS, FOAM 2
100087-001 MOVING HANDLEBAR GRIPS, FOAM 2
10B8291U OWNER MANUAL, Q45 6
1A501301 FLYWHEEL MAGNET 2
10B721WX-1 DECAL, SIDE SHROUD 4
DECAL, CAUTION 4
DECAL, CONSOLE BACK, ALL SILVER 4
DECAL, CONSOLE BACK, ALL BLACK 4
DECAL, PIVOT COVER 4
CHIP PULLER 2
Q45 1.3

Figure 2.2
Figure 2.3
Figure 2.1
Q45 2.1

Figure 2.4
SECTION II: Troubleshooting Tips
2.1 Power/Electrical Issues
The General Service Information Manual provides directions for removing shrouds to access the inside of the unit.
Issue Possible Cause What to Do
No power to the console. Loose or improper plug-in at
wall or unit.
Check that the power supply is properly and
securely plugged in to a working AC power
outlet (wall plug-in).
Check that the power supply cord is properly
and securely inserted into the power input jack
located below the right roller track (Figure 2.1).
Loose or improper electrical
connections within unit.
Unplug the machine, then remove the four (4)
screws securing the console to the console
upright tube.
Unplug and re-plug the cable into the console to
ensure it is a good connection (Figure 2.2).
Check and secure the upper wire harness
connections, at the base of the upright post
(Figure 2.3).
Check and secure the lower wire harness
connections at the controller board and the
servomotor (Figure 2.4).
Plug in the machine to verify power to the
console.
If power is not restored to the console after all the connections have been checked and secured, you may need to
replace the console itself. Refer to Section III for more information.
Q45 2.1
Units with controller mounted near the oor. Units with controller mounted above ywheel

Figure 2.5
Q45 2.2
Figure 2.6

2.2 Resistance Issues
The General Service Information Manual provides directions for removing shrouds to access the inside of the unit.
Issue Possible Cause What to Do
Resistance is too high (rollers
are difcult to move on lowest
resistance setting).
Console setting is incorrect. For shipping, the unit is set on the highest
resistance (level 20) to prevent linkage
movement during shipment. After power
is plugged in, the unit should automatically
reset itself to level 1.
Using the console arrow keys, verify that
the unit is set to level 1.
Brake cable is improperly
installed or aligned.
Inspect the servomotor and cable. The
cable must be installed correctly, positioned
to wrap around the top of the servomotor
pulley as it rotates counterclockwise to
increase resistance. On level one, the
cable and pulley should be positioned as
shown in Figure 2.5, with the notch on the
pulley oriented to “10 o’clock”. (Note: the
arrow in Figure 2.5 is for illustration only;
no arrow is imprinted on the pulley itself.)
Inspect the cable and brake. The brake
adjuster must be located at the top of its
slot when the machine is set to level 1. Use
a ashlight to look through the right pedal
level slot on the back shroud to verify that
the brake adjuster is in the proper position
(shown in Figure 2.6).
Use a screwdriver to gently push the brake
adjuster up to ensure that it is properly
positioned at the top of its slot.
If the brake is not fully disengaged or the
cable has too much slack when the cable
is properly installed and the brake adjuster
is in its proper position for level 1, you may
need to re-install or adjust the cable. Refer
to Section III for instructions.
Q45 2.2

Figure 2.7
Q45 2.2
Figure 2.8
Nylock
nut
Clevis
bushing
Figure 2.9

Issue Possible Cause What to Do
Resistance is too high (unit
is difcult to pedal on lowest
resistance setting).
Pivot bolts are too tight; pivot
bolts should be snug but not
overly tight.
Pedal the unit for 2-4 minutes. Then stop
and touch each pivot point on the linkages
(Figure 2.7). Any are that is hot to the
touch may be overtightened or may be out
of alignment and should be adjusted.
Loosen and re-tighten all pivot bolts (four
on each side of the machine), beginning
with the pivot bolt where the pedal arm
connects to the top of the adjustable link
assembly. Figure 2.7 shows the locations
of the pivot bolts.
Pedal arm/top of adjustable
link assembly is assembled
improperly; the two actuator
bushings and nylock nuts
may be improperly seated
into the pedal arm clevis.
Loosen the two nylock nuts on the pedal
arm at the top of the adjustable link
assembly (Figure 2.8).
Re-tighten the pedal arm bolt. Make sure it
is properly seated and snug but not overly
tight.
Clevis bushing at the pedal
arm is too tight.
The white plastic actuator nut is held
in place at the pedal arm by the clevis
bushing (Figures 2.8 and 2.9.
Remove the nylock nut.
Use while lithium grease to lubricate
the actuator nut posts where the clevis
bushing slides.
Move the clevis bushing to ensure that it
slides freely.
Replace and tighten the nylock nut.
Q45 2.2

Q45 2.2
Figure 2.11
Figure 2.12
Figure 2.10

Issue Possible Cause What to Do
Resistance is too high (unit
is difcult to pedal on lowest
resistance setting).
Arm pivot shaft collar nut is
too tight; pivot shafts should
feel solid, neither wobbly nor
too tight.
Loosen the two set screws on the collar
nut while holding the pivot shaft in place,
then re-tighten the set screws so that the
handlebars move freely but do not wobble.
The collar nut should be oriented so that
the set screws are positioned toward the
holes on the shaft (toward the middle
of the machine), as illustrated in Figure
2.10. (The white dot in Figure 2.10 is for
illustration only and does not appear on
the actual hex collar.)
Drive belt tension is too high. With your ngers, twist the drive belt
between the belt tensioner and the drive
pulley; it should twist approximately 90º.
To loosen the belt, locate the double nut
setup on the adjuster rod (Figure 2.11).
Loosen the rst one, back off the other one
full turn, then re-tighten the rst. Recheck
the drive belt tension as above, making
sure that slippage does not occur between
the belt and the pulley while pedaling the
unit and when changing direction while
pedaling.
Belt tracking is off center. The drive belt should ride in the center, not
shifted to the right or left (Figure 2.12). If
it is off center, you may feel some added
resistance and will hear a rubbing or
swishing noise.
Inspect the belt tensioner (Figure 2.11).
If it is bent, causing the belt to be off
center, replace it following the directions in
Section III.
Q45 2.2

Q45 2.2
Figure 2.13
Figure 2.14
Figure 2.16
Figure 2.15